Apparatus for winding wire and the like

ABSTRACT

A wire winding apparatus reciprocates a wire along the length of a drum so that wire is wound around the drum in uniform layers. The limits of reciprocation of the wire are controlled by limit switches whose positions are adjusted in response to the tension of the wire just before it is reciprocated. Before being reciprocated, the wire passes over a pivotally mounted counterbalanced pulley with the pivotal movement of the pulley, in response to the tension of the wire, controlling a mechanism for adjusting the limit switches to obtain uniform layers of wire around the drum.

I United States Patent [151 3,677,483 Henrich [45] July 18, 1972 [s41APPARATUS FOR WINDING WIRE AND 3,289,956 12/1966 Sjogren ..242/1ss.4 xTHE LIKE 3,413,834 12/1968 Kovaleski... ..242/25 X 3,097,815 7/1963Smith et a1. ....242/158.4 R [72] Inventor: Werner Hennch, 6349l-lorbach (Dlllkres), am wachtglpfel, Germany Primary Examiner-StanleyN. Gilreath [22] Filed; Feb. 4 1970 Assistant ExaminerMilton GersteinAttorney-Edmund M. Jaskiewicz [21] Appl. No.: 8,523

ABS (ACT [30] Foreign Application Priority Data A wire winding apparatusreciprocates a wire along the length of a drum so that wire is woundaround the drum in uniform Sept. 12, 1969 Germany ..P 19 46 220.5layers. The limits of reciprocation of the wire are controlled by limitswitches whose positions are adjusted in response to g the tension ofthe wire just before it is reciprocated. Before being reciprocated, thewire passes over a pivotally mounted [58] Field of Search ..242/25 A, 25R, 157.1, 158.4 counterbalanced p y with the pivotal movement of the pley, in response to the tension of the wire, controlling a [56]References Cited mechanism for adjusting the limit switches to obtainuniform UNITED STATES PATENTS layers of wire around the drum 3,038,6746/1962 Wahl ..242/25 R 6 Clairm, 5 Drawing Figures Patented July18, 19723,677,483

3 Sheets-Sheet l Fig.1

WERNER HENRxCH ATTORNEY Patented July 18, 1972 3,677,483

3 Sheets-She s? 2 mvai'wzp WERNER HENRICH Patented July 18, 1972 3Sheets-Sheet (5 REGULATOR SPEED MOTOR I FIG. 5

INVENTOR WERNER HENRICH ATTORN EY APPARATUS FOR WINDING WIRE AND THELIKE The present invention relates to an apparatus for winding wire andthe like, more particularly, to a mechanism for winding wire in uniformlayers around a drum.

In order to wind wire uniformly around a drum, wire winding machineshave been provided with a mechanism to reciprocate the wire back andforth along the length of the drum so that the wire is wound in uniformlayers thereon. The limits of reciprocation of the wire, or the pointsat which the reciprocating movement of the wire must be reversed, mustbe established precisely with respect to the flanges of the drum. If thewire does not shift direction at a point exactly at a flange of the drumthere will result either an accumulation of wire adjacent this flange orthe wire will be wound short of the flange so as to form a gap or recesstherewith. These recesses or accumulations at the flanges areundesirable and various arrangements have been proposed to regulate thereciprocating movement of the wire. A common arrangement comprised stopsor limit switches which were adjusted manually to limit the range of theshifting movement of the wire and to bring a reversal of direction ofthe shifting movement precisely when the wire reaches a flange.

The manual adjustment of such stop or limit switches was disadvantageousin the high-speed production of wire since such adjustment istime-consuming and requires considerable skill on the part of theoperator.

It is therefore the principal object of the present invention to providea novel and improved apparatus for accurately and automaticallyreversing the direction of movement of a wire being shifted along thelength of a drum upon which it is being wound.

It is another object of the present invention to provide a simplifiedmechanism for automatically displacing limit switches which reverse thedirection of movement of the shifting wire in response to the tension ofthe wire as it is being wound around the drum.

It is a further object of the present invention to provide a novel andimproved apparatus for uniformly winding wire and the like around adrum.

According to one aspect of the present invention an apparatus forwinding wire and the like may comprise means reciprocating or shiftingthe wire in directions parallel to the drum in order to wind the wire inuniform layers between the flanges of the drum. Means areprovided forindicating the tension of the wire during the winding operation. Acontrol apparatus is responsive to the tension indicated on the wire andcontrols the limits of the shifting movement of the wire by displacinglimit switches in suitable directions so that the limit switches reversethe shifting movement of the wire precisely at the flanges of the drum.

Other objects and advantages of the present invention will be apparentupon reference to the accompanying description when taken in conjunctionwith the following drawings, which are exemplary, wherein;

FIG. I is a view of the winding mechanism of a wire winding apparatusaccording to the present invention with the drum being shown in section;

FIG. 2 is a view of the apparatus of FIG. 1 taken in the direction ofthe line llll;

FIG. 3 is a schematic view showing the limit and control switches ingreater detail;

FIG. 4 is a view similar to that of FIG. 3 but showing the contact armsof the switches as actuated by the pulley; and

FIG. 5 is an electrical circuit diagram showing diagrammatically thecontrol system of the apparatus of the present invention.

Proceeding next to the drawings wherein like reference symbols indicatethe same parts throughout the various views a specific embodiment of thepresent invention will be described in detail.

As may be seen in FIGS. 1 and 2, a motor 1 rotates adrum 2 upon which awire 3 is wound. The wire 3 is shifted or rcciprocatcd by means of apulley or roller 4 in directions parallel to the rotary axis of the drumas indicated by a doubleended arrow 5. The pulley 4 is repeatedlyshifted within a range by means of a known shifting mechanism 30. Byshifting the wire in this manner it is wound in successive uniformlayers around a core 8 of the drum 2 and between flanges 6 and 7.

The points at which the shifting movement of the pulley 4 are reversedare determined by limit switches 9 and [0 which actuate the shiftingmechanism 30. When the limit switches 9 and 10 are not properlypositioned a recess 11 as indicated adjacent the flange 6 or anaccumulation 12 adjacent the flange 7 may occur. In order to guide thewire 3 to fill the recess I1 and to prevent subsequent formation of suchrecesses the limit switch 9 must be displaced slightly in the lefthanddirection as viewed in FIG. I. In a similar manner, in order to removethe accumulation I2 and to prevent subsequent formation of suchaccumulations the limit switch 10 must be also displaced a shortdistance in the Iefthand direction.

The wire 3 is delivered to the shifting pulley 4 over a counterbalancedpulley I3 pivotable about a shaft 14 against the force of acounterweight 13A or a spring. Wire tension indicating devices ofvarious forms have been generally provided in wire drawing machines inorder to prevent breaking of the wire, particularly when the wire isvery thin, when the winding speed of the drum becomes too high and thetension on the wire becomes too great. 0n the other hand, when therotary speed of the winding drum is too slow there is a danger of thewire being loosely wound upon the drum. In a conventional apparatus, thewire was thus fed to a winding drum over a compensating orcounterbalanced pulley which is mounted for angular or linear movement.The magnitude of deflection of the pulley or the magnitude of linearmovement of the pulley in one or the other direction thus constitutes anindication of the tension exerted upon the wire. The magnitude ofdeflection of such a pulley was thus employed for continuouslyregulating the rotary speed of the winding drum. Such a compensatingpulley may be employed in the present invention for establishing thepoints at which the wire shifting pulley is to reverse direction. Thisuse of the pulley is possible since it has been discovered that where arecess, such as I1, is formed near a flange of the drum the tension ofthe wire in such an area is reduced. Conversely, the tension on the wireis increased when wire accumulates adjacent a flange such as at 12 inFIG. I. As discussed above, these recesses or accumulations are formedwhen the change of direction of the wire shifting device occurs eithertoo soon or too late with respect to a flange of the drum. Since thetension on the wire is an indication of whether or not the wire is beingwound precisely with respect to a flange of the drum and since thistension is indicated by a compensating pulley as described above, such apulley arrangement may be employed in the present invention to adjustthe shifting points of the wire shifting mechanism.

As shown in FIG. 2, the pulley 13 has an electric contact I5 mounted onits pulley arm. When tension of the wire increases as a result of theformation of an accumulation 12 the speed of the wire will increase andthe pulley 13 will be pivoted downwardly as indicated in FIG. 2. Thecontact 15 will then engage a stationary contact 16 which causes theenergization of an electric motor 18 which operates for a short periodof time and displaces the limit switch 10 to the left during this periodof operation.

Should the wire form a recess 11 as shown in FIG. 1 the speed of thewire will decrease and the tension on the wire will be reduced so thatthe compensating pulley 13 will pivot upwardly to enable its contact 15to engage contact 17. The engagement of contacts 15 and 17 will bringabout an energization of an electric motor 19 which operates to displacethe limit switch 9 a short distance to the left. The positions of thelimit switches 9 and 10 are thus established from the reciprocation ofthe wire 3.

The control arrangement of FIG. 2 may be modified by replacing contacts16 and 17 with a rheostat or variable resistance 20 which is alsoindicated in FIG. 2. The rheostat 20 is connected into a control circuitfor electric motors 18 and 19 so that movement of the pulley contactover the rheostat will vary the voltages supplied to these electricmotors and thus control their speeds and the displacement of the limitswitches 9 and 10. For example, when the voltage is decreased the motor19 will move the limit switch 9 to the left so that the recess 11 willbecome filled with wire. Where there is an overcontrol or the limitswitch 9 is moved too far to the left then an accumulation of wire mayoccur in the recess 11. This accumulation would then be removed duringthe next control operation.

The motor 18 will operate in a corresponding manner to displace thelimit switch 10 to the left or to the right depending upon theaccumulation of wire or formation of a recess at flange 7. A limitswitch 9 or 10 is thus, in effect, oscillated into position by thesuccessive reciprocating movements of the wire 3 as it passes over thecompensating pulley 13.

Since the control contacts 16, 17 or rheostat act upon both motors l8and 19 and since motor 18 is actuated only when the wire is being woundnear flange 7 and motor 19 actuated only where wire is being wound nearflange 6, it is desirable to provide a control structure to assure thisoperation. This control structure may comprise a switch 21 which isclosed when the oscillating pulley 4 is being moved toward the left andapproaches flange 6. In its closed position, the switch 21 will close acircuit which connects the motor 19 to a source of electrical energy. Asthe pulley 4 reverses its direction and moves toward the right theswitch 21 will be opened and a flow of current to the motor 19 will beinterrupted. In a similar manner, as the pulley 4 approaches flange 7 aswitch 22 will be closed so as to close a circuit permitting the flow ofcurrent to the motor 18. When both switches 21 and 22 are open whichwill always be the situation when the pulley is not in the region ofeither flange, the rotary speed of the winding motor 1 will be regulatedby a control system actuated by contacts l5, 16, 17 or by the rheostat20.

The switches 21 and 22 are of the type having resilient contact armsextending into the path of movement of the pulley 4 so that the switchesare opened or closed as the pulley 4 moves past the switch. Switches 21and 22 together with switches 9 and 10 are shown in greater detail inFIGS. 3 and 4. As the pulley 4 moves towards the left as indicated bythe doubleended arrow 5 in FIG. 1, the pulley will contact the longercontact arm 21a of switch 21 as well as the longer contact arm 9b ofswitch 9. As the pulley 4 continues its movement to the left it can beseen in FIG. 4 that the pulley will deflect the arms 21a and 9b to bringthe electrical contacts into engagement to close the electrical circuit.

The switch 21 thus provides for control of the motor 19 as the windingwire moves into the region of flange 6 and, similarily, switch 22provides for control of the motor 18 as the wire enters the region offlange 7. In the region of the drum between these two flange regions therotational speed of motor 1 and hence the speed with which the wire iswound upon the drum 2 may be controlled as pointed out above.

A control system showing the relationship between the switches 21 and22, motors 18 and 19, and the rheostat 20 is shown in the electricalcircuit diagram of FIG. 5. The switch 22 is connected to a source ofelectrical energy R and acts upon a relay R, which is also energizedfrom the source R. The energization or non-energization of relay R,connects either of its poles P, or P in circuit. Pole P, is connected toa speed regulating device 31 which is connected to regulate the speed ofmotor 1. The pole P is connected to apply current to the pulley arm ofthe compensating pulley 13. Depending upon the direction of movement ofcompensating pulley 13, an electrical connection is established betweenpole P of the pulley arm and one of the contacts 15, 16 or 17. Thecontact 15 is a neutral contact in that nothing occurs when the pole Pis connected to contact 15.

The contact 16 is connected to the motor 18 through switch 10, to themotor 19 through switch 9, and to the speed regulator 31. The contact 16controls a forward movement (a) and contact 17, which is connected tothe same elements as contact 16, controls reverse movement (b).

At the same time the switch 21 is connected to the current source R andacts upon relay R in the same manner as switch 22 acts upon relay R,described above.

In operation, when electric current is applied to the contact 15 on thecompensating pulley arm nothing will occur independently of the switches21 and 22. This condition will occur when the tension on the wire 3 isuniform resulting from uniforms winding of the wire on the drum 2.

Should the tension on the wire decrease, the compensating pulley willthen establish contact between pole P and contact 17. This connectionwill immediately affect the speed regulator 31 and, depending on theposition of switches 9 or 10, the displacement of the switches by therespective motors 18 or 19.

When the tension on the wire increases, the motors will rotate in thereverse direction through an electrical connection established by thecontact 16.

Should the switch 22 be opened, current will then flow from source Rover pole P, to the speed regulator 31. This will also occur when switch21 is open. Should either switch 22 or 21 be closed, the motors 18 and19 are controlled by means of the compensating pulley 13.

It is thus apparent that the compensating pulley 13 which provides ameasure of the tension upon the wire 3 has three functions according tothe present invention: first, to establish the point at which the wireshifting device reverses direction in the region of one flange of thedrum; second, to establish a second reversal point in the region of theother flange of the drum; and third, to regulate the rotational speed ofthe winding drum. To accomplish these functions the present inventionemploys a control device which employs the wire tension measuring meansto displace the limit switches when the wire is in the region of eitherflange of the drum but the winding speed of the drum is regulated in theconventional manner by the wire tension indicating means when theshifting wire is in the intermediate space between the two flangeregions.

It is also within the scope of this invention to modify the controlarrangement so that a series of timed pulses are delivered to each ofthe displacing electric motors. By actuating the motors in this mannerthe respective limit switches will be displaced gradually and will thusresult in a gradual fillingup of a recess by the wire or in a gradualreduction of an accumulation of wire.

It is understood that this invention is susceptible to modification inorder to adapt it to different usages and conditions and, accordingly,it is desired to comprehend such modifications within the invention asmay fall within the scope of the appended claims.

What is claimed is:

1. In an apparatus for winding wire and the like in uniform layers upona drum so that the layers terminate at the drum flanges, the combinationof means reciprocating the wire in directions parallel to the drum alongthe length thereof for winding wire in uniform layers between theflanges of a drum, means for indicating the tension on a wire as it isbeing wound on a drum, means responsive to said tension indicating meansfor controlling the limits of movement of said reciprocating means sothat wire is wound uniformly upon the drum along the length thereofbetween the drum flanges, limit switch means responsive to thereciprocating wire for actuating said reciprocating means to reverse thedirection of reciprocation of the wire, means responsive to said controlmeans for displacing said limit switch means to adjust the range ofreciprocation of said reciprocating means to obtain uniform winding ofthe wire, and first and second means in the regions of the first andsecond flanges respectively of the drum for rendering operative saidlimit switch displacing means.

2. In an apparatus as claimed in claim 1 wherein said tension indicatingmeans comprises a pivotally mounted pulley over which the wire is passedbefore being reciprocated, means for counterbalancing said pulleyagainst the tension of the wire thereon, said control means beingactuated in response to the pivotal movement of said pulley.

3. In an apparatus as claimed in claim 2 wherein said control meanscomprises first and second contacts spaced oppositely from each other inthe pivoting path of said pulley, said limit switch displacing meansbeing advanced in one direction in response to one contact position ofsaid pulley and being reversed in the other direction in response to theother contact position.

4. In an apparatus as claimed in claim I and comprising means responsiveto said control means between said two regions for regulating thewinding speed of the drum.

5. In an apparatus as claimed in claim 4 wherein said means fordisplacing the limit switch means comprises electric motors.

6. In an apparatus as claimed in claim I wherein said tension indicatingmeans comprises a pivotally mounted pulley over which the wire is passedbefore being reciprocated, means for compensating said pulley againstthe tension of the wire thereon, said control means being actuated inresponse to the pivotal movement of said pulley, and said control meanscomprises a rheostat actuated in response to the movement of thepivotable pulley to regulate the speeds of the electric motorsoperatively connected to said limit switch means so as to adjust thepositions of said limit switch means.

1. In an apparatus for winding wire and the like in uniform layers upona drum so that the layers terminate at the drum flanges, the combinationof means reciprocating the wire in directions parallel to the drum alongthe length thereof for winding wire in uniform layers between theflanges of a drum, means for indicating the tension on a wire as it isbeing wound on a drum, means responsive to said tension indicating meansfor controlling the limits of movement of said reciprocating means sothat wire is wound uniformly upon the drum along the length thereofbetween the drum flanges, limit switch means responsive to thereciprocating wire for actuating said reciprocating means to reverse thedirection of reciprocation of the wire, means responsive to said controlmeans for displacing said limit switch means to adjust the range ofreciprocation of said reciprocating means to obtain uniform winding ofthe wire, and first and second means in the regions of the first andsecond flanges respectively of the drum for rendering operative saidlimit switch displacing means.
 2. In an apparatus as claimed in claim 1wherein said tension indicating means comprises a pivotally mountedpulley over which the wire is passed before being reciprocated, meansfor counterbalancing said pulley against the tension of the wirethereon, said control means being actuated in response to the pivotalmovement of said pulley.
 3. In an apparatus as claimed in claim 2wherein said control means comprises first and second contacts spacedoppositely from each other in the pivoting path of said pulley, saidlimit switch displacing means being advanced in one direction inresponse to one contact position of said pulley and being reversed inthe other direction in response to the other contact position.
 4. In anapparatus as claimed in claim 1 and comprising means responsive to saidcontrol means between said two regions for regulating the winding speedof the drum.
 5. In an apparatus as claimed in claim 4 wherein said meansfor displacing the limit switch means comprises electric motors.
 6. Inan apparatus as claimed in claim 1 wherein said tension indicating meanscomprises a pivotally mounted pulley over which the wire is passedbefore being reciprocated, means for compensating said pulley againstthe tension of the wire thereon, said control means being actuated inresponse to the pivotal movement of said pulley, and said control meanscomprises a rheostat actuated in response to the movement of thepivotable pulley to regulate the speeds of the electric motorsoperatively connected to said limit switch means so as to adjust thepositions of said limit switch means.